Prefabricated wall panel

ABSTRACT

A low cost prefabricated wall panel comprised by an internal metallic grid structure incorporating a plurality of sandwiched cardboard strips, two cardboard sheet covers, a fire proof substance applied to both cardboard sheet covers and to the wall panel edges and means for linking other panels. The internal cardboard core acts as a sound and thermal insulator, which helps to lower the energy consumption used for cooling and heating inside the construction.

A. FIELD OF THE INVENTION

The present invention is related to prefabricated walls and moreparticularly to a prefabricated wall panel comprised by sandwichedcardboard supported by an iron structure.

B. DESCRIPTION OF THE RELATED ART

There are well known the prefabricated walls comprised by a plurality ofsuperposed flat panels.

Many of the panels forming the prefabricated walls are made of wood or acombination of other materials such as polyurethane, plastic, etc. forproviding a number of desirable characteristics such as convenient soundand/or temperature insulation properties. Furthermore, a fire proof orwater proof covering may be included in order to comply with localregulations.

A space divider is disclosed in the U.S. Pat. No. 4,706,422 whichcomprises two perforated walls with two opposite edges inturned to mateto form cavities to hold acoustic bats therebetween and includingintersecting stiffeners and means to hold a pull-over fabric cover andincluding apertures in end closures to engage forming and locating meansfor the panels and for attaching shelving.

The space divider disclosed by the Pat. No. 4,706 422, as well as manyof the wall panels currently in the market, have a relatively complexinternal structure which use expensive materials and need qualifiedworkmanship for its assembly, which raises the total cost of the wallpanel.

Such kinds of wall panels, given its high cost, are more suited forresidential and commercial use, and its acquisition by low resourcesindividuals or entities is very difficult.

In countries under development or undeveloped, it is very usual that inzones having high poverty rates, the houses are built of inadequate,unsuitable and dangerous materials, such as cardboard, iron sheets andwaste material. Therefore, if it weren't for its high cost the use ofprefabricated wall panels for building or modifying low resources homeswould be ideal since they are very durable, resistant and areeconomically and easily installed.

Therefore, it would be highly desirable to have a low cost prefabricatedwall panel which may be acquired by low resources families in order tobuild or modify their houses or used by low budget constructions.

In view of the above referred need, applicant developed a fire proofprefabricated wall panel comprised by sandwiched cardboard supported byan iron structure only.

The prefabricated wall panel is specifically comprised by an internalmetallic grid structure incorporating a plurality of sandwichedcardboard strips, two cardboard sheet covers, a fire proof substanceapplied to both cardboard sheet covers and to the wall panel edges andmeans for linking other panels.

Thanks to the use of the above described materials, applicant'sprefabricated wall panel is fire proof, very light, has a highresistance and a very low cost, ideal for build or modify low resourceshomes or budget constructions.

Furthermore, the internal cardboard core acts as a sound and thermalinsulator, which helps to lower the energy consumption used for coolingand heating inside the construction.

Finally, the external fire proof covering provides security in its useand weather or humidity resistance, thus prolonging the useful life ofthe wall panel.

SUMMARY OF THE INVENTION

It is therefore a main object of the present invention to provide a lowcost prefabricated wall panel.

It is also a main object of the present invention to provide aprefabricated wall panel having the above disclosed nature comprising aninternal metallic grid structure incorporating a plurality of sandwichedcardboard strips, two cardboard sheet covers, a fire proof substanceapplied to both cardboard sheet covers and to the wall panel edges andmeans for linking other panels.

It is still another main object of the present invention to provide aprefabricated wall panel having the above disclosed nature, which isfire proof, very light, has a high resistance and a very low cost, idealfor build or modify low resources homes or budget constructions.

It is another object of the present invention to provide a prefabricatedwall panel having the above disclosed nature in which, the internalcardboard core acts as a sound and thermal insulator, which helps tolower the energy consumption used for cooling and heating inside theconstruction.

It is a further object of the present invention to provide aprefabricated wall panel having the above disclosed nature in which theexternal fire proof covering provides security in its use and weather orhumidity resistance, thus prolonging the useful life of the wall panel.

These and other objects and advantages of the prefabricated wall panelof the present invention will become apparent to those persons having anordinary skill in the art, from the following detailed description ofthe embodiments of the invention which will be made with reference tothe accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective frontal view of a portion of the prefabricatedwall panel in accordance with the present invention having one of itscardboard sheets covers removed showing its internal structure.

FIG. 2 is a view of a lateral cut of the prefabricated wall panel inaccordance with the present invention showing its internal structure.

DETAILED DESCRIPTION OF THE INVENTION

The prefabricated wall panel will now be described making reference to apreferred embodiment thereof, which is shown in the accompanyingdrawings wherein the same signs and numbers refer to the same parts ofthe shown figure, wherein the prefabricated wall panel of the presentinvention comprising:

-   -   an internal metallic grid structure having:        -   a plurality of metallic galvanized horizontal rods 1, 1′            having a square shaped cross section and a size of ½″× 1/2            ″;        -   a plurality of metallic galvanized vertical rods 2, 2′            having a square shaped cross section and a size of ½″×½″,            intersecting the plurality of horizontal rods 1, 1′ and            joined thereof by welding at the intersecting points 3,            forming a grid having a plurality of quadrangular cells 4;    -   a solid cardboard quadrangular body core formed by a plurality        of sandwiched cardboard strips, all joined by means of an        adherent substance, said quadrangular body core having a first 5        and a second 6 longitudinal edges, a first and a second lateral        edge (not shown), and a superior and an inferior edge 7, 8 and        composed by:        -   a plurality of quadrangular sections 9, each one lodged            inside a cell 4; and        -   a first 10 and a second 11 layer surrounding the plurality            of quadrangular sections 9 and the metallic structure;        -   a first “F” and a second “S” external quadrangular cardboard            cover, covering the first 10 and second 11 layer            respectively and joined thereof by means of an adherent            substance, each external quadrangular cardboard cover “F”,            “S”formed by a plurality of sandwiched cardboard sheets            joined together by means of an adherent substance;    -   a fire proof and water resistant layer surrounding the entire        wall panel having a textured finish.

In a preferred embodiment, the panel width is 2″ and its total area is0.90×1.25 mts., furthermore, in said preferred embodiment, there are twovertical 13 and horizontal 14 rods, forming nine cells per panel.

The ends of each vertical 13 and horizontal 14 rod project out of thewall panel and serve as means for linking the wall panel to other wallpanels or directly to other structure such as a headframe by means ofanchors or welding for example.

The fire proof and water resistant layer 12 provides additional rigidityto the panel and at the same time gives a pleasant texture at the touchand finish to the panel.

Normally, the panels are installed between headframes having verticalrodding in such way that the ends of the vertical rods 14 projecting outof the panel, are linked to the headframe vertical rodding.

Once the panels are linked to the headframes, a cover of gypsum oranother substance may be applied to the panels, headframes and inbetween the panels and headframes in order to give the appearance of acontinuous wall to all the linked panels and finally a cover of paintingmay be applied in order to improve the appearance of the linked panelsand headframes which appear to be a continuous wall.

As previously described, the horizontal 1, 1′ rods intersect vertical 2,2′ rods and are welded at the intersecting points 3. In a preferredembodiment, each horizontal rod is located over each vertical rod andwelded at the intersecting points 3 or vice versa, however in otherembodiments, the metallic structure may be constructed in one piece, andin such embodiment, the horizontal and vertical rods intersect to eachother at the same plane.

Although it was described that the horizontal 1, 1′ and vertical 2, 2′rods project out of the wall panel and serve as means for linking thewall panel to other wall panels or structures, it may be possible thatthe horizontal 1, 1′ and vertical 2, 2′ rods remain inside the wallpanel, and in such way, the linking means may comprise a clamp system,rails or any other suitable linking means which may result adequate forthe characteristics of the construction in which the wall panels will beinstalled. Also, depending of such specific needs, the core body of thewall panel may be made of paper, corrugated cardboard or any othersuitable package material.

Furthermore, although it was described that the prefabricated wall panelof the present invention may be used mainly for the assembly of wallstructures, it may be possible to use it for assembling roof structuressuch as roof subframes.

The following are test examples that show the resistance of theprefabricated wall panel of the present invention under stress.

EXAMPLE 1

A prefabricated wall panel in accordance with the present inventionhaving a size of 35.4″×47.24″×1.96″and a metallic grid including fourhorizontal rods and 3 vertical rods each having a size of ½″×½″ formingsix quadrangular cells, was submitted to a test for determining itscharge capacity when applying a flexing force.

The test was carried out by placing the wall panel over four metallicperimetric supports each having a width of 5″. The force was evenlyapplied to each cell by means of two iron plates longitudinally placedover the wall panel so each plate contacted a row of three quadrangularcells, each plate having a size of 9.84″×9.84″×1″. A downward force wasapplied to both plates by means of a pair of two elongated metallicmembers connected to a hydraulic cylinder and perpendicularly orientedwith respect of the iron plates.

The force was quantified by means of a charge cell having a resolutionof 11.02 lbs and a special gauge was used to evaluate the verticaldisplacement at the center of the panel. The force was applied until thepanel failed thus obtaining a maximum endurance force of 6,779.21 lbsand a maximum vertical displacement of approximately 2.36″.

The following graphic show the values of force versus verticaldisplacement until half of the maximum endurance force, showing a linealperformance.

EXAMPLE 2

A prefabricated wall panel in accordance with the present inventionhaving a size of 15.74″×19.68″×1.96″ and a metallic grid including twohorizontal rods and two vertical rods each having a size of ½″×½″forming one complete quadrangular cells, was submitted to a test fordetermining its charge capacity when applying an axial force.

The test was carried out by placing the wall panel over one of itslongitudinal sides. The force was evenly applied over the total lengthof the panel by means of a horizontal elongated metallic memberconnected to a hydraulic cylinder.

The force was quantified by means of a charge cell having a resolutionof 11.02 lbs and a special gauge was used to evaluate the verticaldeformation of the panel. The force was applied until the panel failedthus obtaining a maximum endurance force of 8,126.23 lbs and a maximumvertical deformation of 0.095″

The following graphic show the values of force versus verticaldeformation until half of the maximum endurance force.

Finally it must be understood that the prefabricated wall panel, of thepresent invention, is not limited exclusively to the embodiments abovedescribed and illustrated and that the persons having ordinary skill inthe art can, with the teaching provided by the invention, to makemodifications to the prefabricated wall panel of the present invention,which will clearly be within of the true inventive concept and of thescope of the invention which is claimed in the following claims.

1. A prefabricated panel comprising: an internal structure; a solidpackage material core body supported by the internal metallic structure;a fire proof and water resistant cover surrounding the core body; andmeans for linking said prefabricated panel to other prefabricated panelor structure.
 2. A prefabricated wall panel as claimed in claim 1,wherein the metallic structure comprising: a plurality of horizontalmetallic rods; a plurality of vertical metallic rods, intersecting theplurality of horizontal rods and joined thereof at intersecting points,forming a grid having a plurality of cells.
 3. A prefabricated wallpanel as claimed in claim 1, wherein the internal structure comprising ametallic grid structure forming a plurality of cells.
 4. A prefabricatedwall panel as claimed in claim 1, wherein the core body is comprised bya plurality of sandwiched cardboard strips, all joined by means of anadherent substance.
 5. A prefabricated wall panel as claimed in claim 1,wherein the metallic structure comprising: a plurality of horizontalrods and a plurality of vertical rods, intersecting the plurality ofhorizontal rods and joined thereof at intersecting points, forming agrid having a plurality of cells, and wherein the core body is comprisedby a plurality of sandwiched cardboard strips, all joined by means of anadherent substance, said quadrangular body core having a first and asecond longitudinal edges, a first and a second lateral edge, and asuperior and an inferior edge and composed by: a plurality ofquadrangular sections, each one lodged inside a cell; and a first and asecond layer surrounding the plurality of quadrangular sections and themetallic structure.
 6. A prefabricated wall panel as claimed in claim 1,wherein the means for linking said prefabricated panel to otherprefabricated panel or structure comprise a plurality of horizontal andvertical rods joined to the internal structure.
 7. A prefabricated wallpanel as claimed in claim 1, wherein the metallic structure comprising:a plurality of horizontal metallic rods; a plurality of verticalmetallic rods, intersecting the plurality of horizontal rods and joinedthereof at intersecting points, forming a grid having a plurality ofcells; and wherein the horizontal and vertical rods project out of thewall panel and serve as means for linking the wall panel to other wallpanels or structures.